A control system for compensating a hysteresis band of a switched reluctance (SR) machine having a rotor and a stator is provided. The control system may include a converter circuit and a controller. The converter circuit may be operatively coupled to the stator and include a plurality of switches in selective communication with each phase of the stator. The controller may be in communication with each of the stator and the converter circuit, and configured to monitor at least one phase current of the SR machine relative to a current threshold of the hysteresis band, determine an adjustment value based on a difference between the phase current and the current threshold if the phase current exceeds the current threshold, and compensate the current threshold by the adjustment value.
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9. A method of controlling hysteresis compensation, the method comprising the steps of:
monitoring at least one parameter relative to each of an upper threshold and a lower threshold of a hysteresis band;
determining an adjustment value based on a difference between the at least one parameter and any exceeded one of the upper and lower thresholds; and
adjusting each of the upper and lower thresholds of the hysteresis band by the adjustment value.
15. A method of providing hysteresis compensation for a switched reluctance (SR) machine having a rotor and a stator, the method comprising the steps of:
monitoring a phase current through at least one phase of the stator relative to each of an upper current threshold and a lower current threshold of a hysteresis band;
determining a difference value between the phase current and any one of the upper and lower current thresholds exceeded by the phase current;
determining an adjustment value based at least partially on the difference value; and
adjusting each of the upper and lower current thresholds of the hysteresis band by the adjustment value.
1. A control system for compensating a hysteresis band of a switched reluctance (SR) machine having a rotor and a stator, the control system comprising:
a converter circuit operatively coupled to the stator and including a plurality of switches in selective communication with each phase of the stator; and
a controller in communication with each of the stator and the converter circuit, the controller being configured to monitor at least one phase current of the SR machine relative to each of an upper current threshold and a lower current threshold of the hysteresis band, determine an adjustment value based on a difference between the phase current and an exceeded one of the upper and lower current thresholds if the phase current exceeds either current threshold, and compensate the current thresholds by the adjustment value.
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The present disclosure relates generally to hysteresis-based controls, and more particularly, to systems and methods of compensating hysteresis-based current control in switched reluctance (SR) machines.
With the growing interest in energy conservation, increasingly more machines, such as mobile industrial work machines or stationary power generation machines, are supplied with electric drive assemblies or systems for operating various tools or functions of the machine. Ongoing developments in electric drives have made it possible for electrically driven machines to effectively match or surpass the performance of mechanically driven machines while requiring significantly less fuel and overall energy. As electric drives become increasingly more commonplace with respect to such machines, the demand for more efficient generators and techniques for controlling same has also increased.
Among the various types of electrically driven machines available for use with such electric drives, switched reluctance (SR) machines have received great interest for being robust, cost-effective, and overall, more efficient. An SR machine is typically used to convert mechanical power received from a primary power source, such as a combustion engine, into electrical power for performing one or more operations of the machine. Additionally, an SR machine may be used to convert electrical power stored within a common bus or storage device into mechanical power. SR machines can similarly be used in conjunction with other generic power sources, such as batteries, fuel cells, and the like. Still further, SR machines can also be used with stationary machines having conventional power sources such as windmills, hydro-electric dams, or any other generic power source commonly used for stationary applications.
A typical SR machine essentially includes a multi-phase stator that is electrically coupled to an electric drive circuit, and a rotor that is rotatably positioned within the stator. In a motoring mode of operation, the electric drive selectively enables gates or switches associated with each phase of the stator so as to cause electromagnetic interactions between the stator and rotor poles and rotate the rotor relative to the stator at a desired torque and/or speed. Alternatively, in a generating mode of operation, the electric drive may be configured to receive any electrical power which may be induced by mechanical rotations of the rotor relative to the stator. The electric drive may use the electrical power that is induced during the generating mode to power auxiliary or accessory devices of the associated work machine, or in some cases, store the electrical power in an energy storage device.
Conventional schemes for controlling SR machines may involve operating two switches associated with each phase of the stator, or current chopping, in one of a number of different operating modes. For instance, control for operating modes corresponding to a first range of speed tasks may be conducted by hard chopping current to the two switches of each phase, while control for a second range of speed tasks may be conducted by soft chopping current to the two switches of each phase. A conventional hard chopping routine sources a pulsed phase current by simultaneously opening and closing both switches of each phase at the required switching frequency, whereas a conventional soft chopping routine sources soft pulsed phase current by holding one of the switches closed while opening and closing the other switch at the switching frequency.
Although functional, conventional SR machines offer significant room for improvements in terms performance and efficiency. One commonly shared area of interest relates to improving the accuracy of torque production, or maintaining the average torque output of a machine, such as an SR machine, at a more consistent level. The average torque output may be better managed by improving the switching strategy or chopping control scheme being applied per phase of the SR machine. However, adjustments in the chopping scheme are limited due to various hardware constraints. Among other things, the switching frequency as well as the turn-off point for each phase cannot be adjusted without adversely affecting machine components, thus leaving only the turn-on point of each phase as a point of adjustment.
The turn-on and turn-off points of each phase may be managed by the respective bounds or limits of a predefined hysteresis band. These limits of the hysteresis band may further be preconfigured according to any one of a number of different techniques. For example, some techniques establish a generally wider hysteresis band to accommodate for a wider range of phase current fluctuations, while some other techniques adjust hysteresis bands based on rotor position by affecting machine inductance. However, use of such techniques often results in higher currents, which further leads to increased losses in power, higher operational temperatures and increased risks of over-current conditions.
In order to help prevent such increases in current, other techniques have also been used which engage only the turn-on point, or the lower limit of the hysteresis band, to be adjusted and lowered. However, due to machine inductance, current rise rates, and in some instances, current fall rates, the lower limit of the hysteresis band can exhibit a drooping effect. A drooping effect may be caused by decreases in machine inductance, which cause the current to rise at faster rates. Moreover, as the current rises at faster rates, more time is required to allow the current to sufficiently fall in order to satisfy the switching frequency of the machine. In response, the average observed phase current gradually decreases, or droops, and increasingly departs from the initially desired or target phase current. Such decreases in the average phase current further lead to lower average torque production and an overall reduction in torque accuracy.
Accordingly, there is a general need for improved hysteresis-based controls which perform with more consistency and accuracy while satisfying various hardware constraints. In one particular instance, there is a need for an improved hysteresis-based control for use with current chopping in SR machines which overcomes the deficiencies identified above. Specifically, there is a need to improve the accuracy of the torque produced by an SR machine, and more consistently maintain a desired average torque output thereof. Moreover, there is a need to better maintain the average phase current of the machine at a consistent level while staying within the limits of the machine's switching frequency without introducing high magnitudes of current.
In one aspect of the present disclosure, a control system for compensating a hysteresis band of a switched reluctance (SR) machine having a rotor and a stator is provided. The control system may include a converter circuit and a controller. The converter circuit may be operatively coupled to the stator and include a plurality of switches in selective communication with each phase of the stator. The controller may be in communication with each of the stator and the converter circuit, and configured to monitor at least one phase current of the SR machine relative to a current threshold of the hysteresis band, determine an adjustment value based on a difference between the phase current and the current threshold if the phase current exceeds the current threshold, and compensate the current threshold by the adjustment value.
In another aspect of the present disclosure, a method of controlling hysteresis compensation is provided. The method may include the steps of monitoring at least one parameter relative to a hysteresis band extending between an upper threshold and a lower threshold; determining an adjustment value based on a difference between the at least one parameter and any exceeded one of the upper and lower thresholds; and adjusting each of the upper and lower thresholds of the hysteresis band by the adjustment value.
In yet another aspect of the present disclosure, a method of providing hysteresis compensation for an SR machine having a rotor and a stator is provided. The method may include the steps of monitoring a phase current through at least one phase of the stator relative to each of an upper current threshold and a lower current threshold of the hysteresis band; determining a difference value between the phase current and any one of the upper and lower current thresholds exceeded by the phase current; determining an adjustment value based at least partially on the difference value; and adjusting each of the upper and lower current thresholds of the hysteresis band by the adjustment value.
Reference will now be made in detail to specific embodiments or features, examples of which are illustrated in the accompanying drawings. Generally, corresponding reference numbers will be used throughout the drawings to refer to the same or corresponding parts.
During a generating mode of operation, as the rotor 116 is rotated within the stator 118 by the power source 102, electrical current may be induced within the stator 118 and supplied to the converter circuit 122. The converter circuit 122 may in turn convert the electrical signals into an appropriate direct current (DC) voltage for distribution to the various electrical loads 114 of the machine 100. Additionally, the SR machine 110 may be enabled to cause rotation of the rotor 116 in response to electrical signals that are provided to the stator 118 from the common bus 120, for instance, during a motoring mode of operation. The common bus 120 may include a positive line 124 and a negative or ground line 126 across which a common DC bus voltage may be communicated to one or more loads 114 of the machine 100 coupled thereto. For instance, the converter circuit 122 may provide a DC signal to be transmitted through the common bus 120 and to a rectifier circuit where the DC voltage may be converted into the appropriate alternating current (AC) signals for driving the one or more traction motors, or the like, for causing motion of the machine 100 via the traction device 106. The common bus 120 may also communicate the common DC voltage to other loads 114 of the machine 100, such as components of a hybrid system, electrically driven pumps, electrically driven fans, and the like.
Still referring to
The controller 130 of
Such rotor speeds may be classified with respect to a base speed that is specific to the given SR machine 110 and/or the load associated therewith. Furthermore, the base speed may generally be defined as the maximum speed at which the SR machine 110 is able to output generally constant torque before torque output begins to decrease proportionally with rotor speed. As an example, relatively high speeds may be classified as rotor speeds approximately exceeding the base speed, while relatively low speeds may be classified as rotor speeds approximately ranging between zero and base speeds. Nominal speeds may correspond to rotor speeds which approximate the base speed. Such algorithms may additionally or alternatively include predefined control maps or lookup tables which may suggest to the controller 130 a predefined control scheme that best corresponds to a given situation and optimizes performance. Algorithms or sets of instructions and conditionals may be preprogrammed or incorporated into a memory of the controller 130 by means commonly known in the art.
During propulsion or an otherwise motoring mode of operation, the controller 130 may adjust the manner in which current is supplied to each phase leg of the stator 118 according to the observed rotor speed so as to optimize machine performance and efficiency. For example, if the rotor speed is determined to be relatively high, the controller 130 may adopt a single pulse mode of operation in which both switches 132 associated with each phase leg of the stator 118 are closed so as to operate the SR machine 110 in a substantially constant power range of output. Alternatively, if the rotor speed corresponds to nominal or relatively low speeds, the controller 130 may regulate the phase current using, for instance, either a hard chopping control scheme or a soft chopping control scheme. Although other designations may exist, hard chopping schemes may generally be more adapted for use within regions of machine operation where current regulation is desired but controllability poses an issue. Such regions may include retarding regions of operation or regions in which current tracking is more critical. In a hard chopping scheme, the controller 130 may simultaneously open and close both switches 132 of each phase leg at the required frequency so as to maintain a substantially constant torque range of output. In a soft chopping scheme for a motoring mode of operation, the controller 130 may continuously close one of the two switches 132 while opening and closing the remaining switch 132 of each phase leg to maintain a substantially constant torque output.
One or more of the hard chopping and soft chopping control schemes may be managed at least in part by a hysteresis control scheme 140, one application of which is generally illustrated by example in
However, as shown in
Thus, in order to maintain the average phase current through each phase of the stator 118 at a desired target current without increasing switching frequency, the controller 130 may be configured or preprogrammed to dynamically compensate the hysteresis band as needed per switching period and per phase of the stator 118 according to the algorithm or method 154 shown in
With reference to one implementation for use with an SR machine 110, the algorithm or method 154 may initially configure the controller 130 to standby and determine when the switches 132 are first engaged, as shown in step 154-1 of
In step 154-3, the controller 130 may be configured to determine the actual phase current 150, for instance, as measured at the point of expiration of the period counter. The controller 130 may additionally compare the measured phase current 150 to the raw limits of the hysteresis band 142, or the predefined upper and lower current thresholds 146, 148 to determine if the phase current 150 is within the desired hysteresis band 142. If the phase current 150 is found to be within acceptable limits, the controller 130 may proceed to step 154-4 and leave the hysteresis band 142 as is without applying any compensation thereto. The controller 130 may then return to step 154-1 and standby for the next switching event. Alternatively, if the phase current 150 is determined to fall below the lower current threshold 148 and/or lie outside of the raw limits of the hysteresis band 142, the controller 130 may be configured to proceed to step 154-5. During step 154-5, the controller 130 may be able to apply the appropriate compensation to the hysteresis band 142 for the immediate cycle or switching period 152 prior to returning to the standby step 154-1 and prior to proceeding to the next switching event.
When compensation of the hysteresis band 142 is desired, the compensation step 154-5 of the algorithm 154 of
Upon determining the adjustment value 160 in step 156-2, the controller 130 during step 156-3 may then apply the adjustment value 160 to the hysteresis band 142 and immediately restart the period counter. Specifically, the controller 130 may apply the adjustment value 160, or half of the difference value 158, substantially equally to each of the upper and lower current thresholds 146, 148 of the hysteresis band 142. As shown in
Each iteration of the hysteresis compensation subroutine 156 of
The controller 130 may so operate according to the methods 154, 156 of
Industrial Applicability
In general, the foregoing disclosure finds utility in generally any hysteresis-based scheme for controlling and/or limiting one or more parameters, signals, transmissions, outputs, and the like, within a desired range. The foregoing disclosure more particularly finds utility in various industrial applications, such as the farming, construction and mining industries in providing smoother and more efficient control of machines typically used in association with work vehicles and/or machines, such as tractors, backhoe loaders, compactors, feller bunchers, forest machines, industrial loaders, skid steer loaders, wheel loaders, and the like. The present disclosure also finds utility in various applications with stationary machines, such as windmills, hydro-electric dams, and the like.
Moreover, the disclosed control systems and methods may be applied to essentially any hysteresis-based control system where compensation of hysteresis limits is applicable, for example, for use with electric drive systems and machines having switched reluctance (SR) or other comparable machines commonly used in the art. More specifically, the systems and methods disclosed herein assist controls for current chopping schemes used in SR machines which, among other things, help maintain an average phase current that is more consistent with a target phase current so as to provide more consistent average torque output and improve overall torque accuracy. Furthermore, the present disclosure enables hysteresis-based compensations which provide more consistent torque output while satisfying the switching frequency of the associated machine and without increasing risks associated with over-current conditions.
From the foregoing, it will be appreciated that while only certain embodiments have been set forth for the purposes of illustration, alternatives and modifications will be apparent from the above description to those skilled in the art. These and other alternatives are considered equivalents and within the spirit and scope of this disclosure and the appended claims.
Wai, Jackson, Khalil, Ahmed, Gerdes, Jesse
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Jul 18 2012 | WAI, JACKSON | Caterpillar, Inc | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 028613 | /0929 | |
Jul 18 2012 | KHALIL, AHMED | Caterpillar, Inc | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 028613 | /0929 | |
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